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D/F MIG Welding Contact Tips

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D/F MIG Welding Contact Tips - General Information

D/F Machine Specialties, family owned and operated since 1966, is a world leader in the design, development, and manufacture of American made MIG (GMAW) & TIG (GTAW) torches for robotic and welding automation equipment, welding products, and consumables. D/F Machine Specialties genuine American made torch contact tips and copper gas nozzles deliver the performance and reliability you need to minimize your production costs while maximizing welding efficiencies! Not only are D/F’s contact tips made domestically in the United States but our copper is also purchased domestically and comes from a mill in the United States, and the copper is drawn in the US. Our raw copper materials that make up our tips and nozzles do not come from China. Wouldn’t you prefer to know that when buying an American product it is not only manufactured in America but the raw materials that make up the product also come from America? Many large manufacturers with robotic assembly lines have not only discovered the advantages of D/F’s superior built torches, but also the advantages of using D/F Machine Specialties genuine American made copper torch tips and copper nozzles which reduce down time for tip changes and increase productivity.

CONTACT TIPS IN MIG WELDING
Make sure the gun tip isn’t worn out or that weld spatter is not on the tip near the exit hole. The contact tip in the gun should be perfectly round and just a few thousandths larger than the wire itself. Worn tips are typically oval and can cause an erratic arc from the random electrical connection and physical movement of the wire inside the worn tip. Genuine D/F Machine Specialties contact tips are precisely made from a wear-resistant copper alloy for superior welding performance. If the contact tip enters the molten weld pool, it should be immediately replaced. For most casual welders, a good rule of thumb to assure high quality welding is to change the tip after every 100 lbs. of wire. For production welding with extreme conditions and duty cycles such as 4-hour arc time, it is recommended that you change a tip every time you finish a part. D/F is famous for a constant and stable arc. It is very safe to assume that if you have any change in weld quality or any change in the arc that the contact tip should already have been changed. Because of the superior performance and reliability of D/F torches, contact tips, and nozzles, it is very easy to perform a brief study to determine the contact tip and nozzle life for a particular job. The result of this study can be used to put measures in place so that the tip can be changed at regular appropriate intervals that will prevent any reduction in weld quality. Another point to remember about contact tips is that they should always be threaded completely into the adapter or torch body and tightened prior to welding to give a smooth flow of welding current and to prevent resistance heating.

AMERICAN MADE
100% of our products are manufactured right here at our facilities, from the American made raw materials to the final product. Factory automation including robotic machining processes and vision inspection systems yields precision and high quality components.

LESS DOWN TIME
High quality, high performance equipment means less down time for repairs, and less changing out of consumable components.

The buzzwords, “Increased Productivity”, “Reduced Down Time”, “Continuous Improvement”, “Share Price”, “ROI”, have all mandated a constant search for what is the D/F way to keep automated welding equipment and facilities running at peak performance.

SHIPPING PRODUCTS GLOBALLY
We deliver welding equipment to the Automotive, Shipbuilding, Steel Service, Mining, Metal Fabrication, Construction, Energy, and General Manufacturing industries.

CUSTOM MANUFACTURING - SPECIAL ORDER PARTS
If you’re looking for a part not listed on our website or in our catalog, be sure to call us. We fabricate special order parts and do limited production runs of torches, nozzles, tips and consumables. D/F continually adds new products to our listings and some parts may not be listed in our catalog.

LIMITED PRODUCTION RUNS - HARD TO FIND PARTS FOR OLDER EQUIPMENT
D/F has a wealth of knowledge, dating back to 1940’s, that includes engineering drawings, programs and use specifications for older equipment, parts and consumables.

We manufacture a complete line of standard size C122 DHP current tips and a complete line of standard size CuCrZr long-life current tips, as well as any custom contact tip configuration you may need. We can make any style of tip, in any quantity, for wires of .030" (.8mm), .035" (.9mm), .045" (1.2mm), .052" (1.4mm), 1/16" (1.6mm), 3/64" (1.2mm), 5/64" (2mm), 3/32" (2.4mm), 1/8" (3.2mm) and other diameters. Each requirement is quoted quickly and accurately to meet your needs.

D/F Machine Specialties barrels are standard equipped with one (1) Water Out & Power Cable and are rated up to 650 amps (continuous duty cycles). These ratings however are dictated by the contact tip. The NCM (slip-in) series of contact tips is rated up to 450 amps (continuous duty cycles). Because of our heavy duty design and superior water cooling on the tip, the less expensive C122 DHP contact tip is all you need. These slip-in tips are fastened by a collet action nut. The wire diameter range with .030”-1/8” with hard/cored wire, and 3/64”-3/32” with aluminum wire. However, if your welding application requires preheat, amperages above 450, or extremely long duty cycles, we recommend you change to the torch model HTM which utilizes the heavy duty threaded CuCrZr series of contact tips.

The barrel models HTM (CuCrZr chromium zirconium copper - Threaded Contact Tip) have a current capacity range up to 650 amperes with one power cable. Some HTM models can also be retrofit to have 2 water/out & power cables increasing the continuous duty cycle rating to 850 amps. Rating will be contingent on the combination of current tip and shielding gas to be used. The models HTM will accommodate wire diameter range with .035”-1/8” with hard/cored wire, and 3/64”-3/32” with aluminum wire.

In some instances C122 DHP is adequate, but for stainless steel and stiff, high column strength or abrasive wires such as Flux cored / Metal cored, CuCrZr is the correct choice. D/F Machine Specialties can increase several key characteristics creating a higher-quality consumable with increased conductivity, even higher softening temperature and improved hardness. This means a reduction in "arc start failures" and increased tip life. Copper Chromium Zirconium (CuCrZr) Tips Increase Productivity.


10789 - .045" (1.15mm) Slip-In
Copper Contact/Current Tip

Copper Contact/Current Tips - 1/4" Diameter Slip-In

ORDERING INFORMATION - 1/4" DIAMETER SLIP-IN
Gun or Barrel Model
Wire Size
Wire Type Code No.
All NCC, NCM (Slip-In Tips)
(Tip provides 1/8" set back)
.030" (.8mm)
.035" (.9mm)
.045" (1.2mm)
.052" (1.4mm)
1/16" (1.6mm)
5/64" (2mm)
Hard
Hard
Hard
Hard
Hard
Hard
10787
10788
10789
10830
10790
10792
All NCC, NCM (Slip-In Tips)
(Tip provides 1/8" set back)
3/64" (1.2mm)
1/16" (1.6mm)
5/64" (2mm)
3/32" (2.4mm)
Aluminum
Aluminum
Aluminum
Aluminum
10781
10782
10823
10783


10885 - .045" (1.15mm) Slip-In
Copper Contact/Current Tip

Copper Contact/Current Tips - 5/16" Diameter Slip-In

ORDERING INFORMATION - 5/16" DIAMETER SLIP-IN
Gun or Barrel Model
Wire Size
Wire Type Code No.
All NCC, NCM (Slip-In Tips)
(Tip provides 1/8" set back)
.030" (.8mm)
.035" (.9mm)
.045" (1.2mm)
.052" (1.4mm)
1/16" (1.6mm)
5/64" (2mm)
3/32" (2.4mm)
7/64" (2.8mm)
1/8" (3.2mm)
Hard
Hard
Hard
Hard
Hard
Hard
Hard
Hard
Hard
10883
10884
10885
10886
10887
10888
10889
10904
10933
All NCC, NCM (Slip-In Tips)
(Tip provides 3/8" set back)
.035" (.9mm)
.045" (1.2mm)
.052" (1.4mm)
1/16" (1.6mm)
5/64" (2mm)
3/32" (2.4mm)
7/64" (2.8mm)
1/8" (3.2mm)
Cored
Cored
Cored
Cored
Cored
Cored
Cored
Cored
10893
10894
10895
10896
10897
10898
10899
10900
All NCC, NCM (Slip-In Tips)
(Tip provides 1/8" set back)
3/64" (1.2mm)
1/16" (1.6mm)
5/64" (2mm)
3/32" (2.4mm)
1/8" (3.2mm)
Soft
Soft
Soft
Soft
Soft
10902
10935
10888
10936
10933


10795 - .045" (1.15mm) Slip-In
Copper Contact/Current Tip

Copper Contact/Current Tips - 2 1/2" Slip-In 1/4" Diameter

ORDERING INFORMATION - 2 1/2" SLIP-IN 1/4" DIAMETER
Gun or Barrel Model
Wire Size
Wire Type Code No.
All NCC, NCM (Slip-In Tips)
(Tip provides 1/8" set back)
.030" (.8mm)
.035" (.9mm)
.045" (1.2mm)
.052" (1.4mm)
1/16" (1.6mm)
Hard
Hard
Hard
Hard
Hard
10794
10795
10796
10840
10797
All NCC, NCM (Slip-In Tips)
(Tip provides 1/8" set back)
3/64" (1.2mm)
1/16" (1.6mm)
Aluminum
Aluminum
10785
10786


19392 - .045" (1.15mm) Slip-In
Copper Contact/Current Tip

Copper Contact/Current Tips - 2 1/2" Slip-In 5/16" Diameter

ORDERING INFORMATION - 5/16" SLIP-IN 5/16" DIAMETER
Gun or Barrel Model
Wire Size
Wire Type Code No.
All NCC, NCM (Slip-In Tips)
(Tip provides 1/8" set back)
.030" (.8mm)
.035" (.9mm)
.045" (1.2mm)
.052" (1.4mm)
1/16" (1.6mm)
5/64" (2mm)
3/32" (2.4mm)
7/64" (2.8mm)
1/8" (3.2mm)
Hard
Hard
Hard
Hard
Hard
Hard
Hard
Hard
Hard
19390
19391
19392
19393
19394
19711
19726
19396
19727
All NCC, NCM (Slip-In Tips)
(Tip provides 3/8" set back)
.035" (.9mm)
.045" (1.2mm)
.052" (1.4mm)
1/16" (1.6mm)
5/64" (2mm)
3/32" (2.4mm)
7/64" (2.8mm)
1/8" (3.2mm)
Cored
Cored
Cored
Cored
Cored
Cored
Cored
Cored
19400
19401
19402
19403
19404
19405
19406
19720
All NCC, NCM (Slip-In Tips)
(Tip provides 1/8" set back)
3/64" (1.2mm)
1/16" (1.6mm)
5/64" (2mm)
3/32" (2.4mm)
Soft
Soft
Soft
Soft
19407
19408
19728
19409


15117 - .045" (1.15mm) Threaded
CuCrZr - (Cu-Copper Cr-Chromium Zr-Zirconium)
Copper Contact/Current Tip


15106 - .045" (1.15mm) Threaded
CuCrZr - (Cu-Copper Cr-Chromium Zr-Zirconium)
Copper Contact/Current Tip

Copper Contact/Current Tips - 7/16" Diameter Threaded
CuCrZr - (Cu-Copper Cr-Chromium Zr-Zirconium)

ORDERING INFORMATION - 7/16" DIAMETER THREADED
Gun or Barrel Model
Wire Size
Wire Type Code No.
All HTC, HTM, CTW, CW-C, CW-T, MTW
(Threaded Tips)
(Tip provides 1/8" set back)
.035" (.9mm)
.045" (1.2mm)
.052" (1.4mm)
1/16" (1.6mm)
5/64" (2mm)
3/32" (2.4mm)
7/64" (2.8mm)
1/8" (3.2mm)
5/32" (4mm)
Hard
Hard
Hard
Hard
Hard
Hard
Hard
Hard
Hard
15116
15117
15121
15118
15119
15120
15122
15105
15150
All HTC, HTM, CTW, CW-C, CW-T, MTW
(Threaded Tips)
(Tip provides 3/8" set back)
.035" (.9mm)
.045" (1.2mm)
.052" (1.4mm)
1/16" (1.6mm)
5/64" (2mm)
3/32" (2.4mm)
7/64" (2.8mm)
1/8" (3.2mm)
5/32" (4mm)
Cored
Cored
Cored
Cored
Cored
Cored
Cored
Cored
Cored
15101
15106
15112
15107
15108
15109
15110
15111
15113
All HTC, HTM, CTW, CW-C, CW-T, MTW
(Tip provides 1/8" set back)
3/64" (1.2mm)
1/16" (1.6mm)
5/64" (2mm)
3/32" (2.4mm)
1/8" (3.2mm)
5/32" (4mm)
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
15126
15125
15087
15148
15123
15151


15138 - 1/16" (1.6mm) Threaded
CuCrZr - (Cu-Copper Cr-Chromium Zr-Zirconium)
Copper Contact/Current Tip - Tandem

Copper Contact/Current Tips - 7/16" Diameter Threaded - Tandem
CuCrZr - (Cu-Copper Cr-Chromium Zr-Zirconium)

ORDERING INFORMATION - 7/16" DIAMETER THREADED
Gun or Barrel Model
Wire Size
Wire Type Code No.
All HTM-TDP
(Threaded Tips)
(Tip provides 1/8" set back)
.035" (.9mm)
.045" (1.2mm)
.052" (1.4mm)
1/16" (1.6mm)
5/64" (2mm)
3/32" (2.4mm)
7/64" (2.8mm)
1/8" (3.2mm)
Hard/Cored
Hard/Cored
Hard/Cored
Hard/Cored
Hard/Cored
Hard/Cored
Hard/Cored
Hard/Cored
15157
15158
15159
15138
15160
15161
15162
15163
All HTM-TDP
(Threaded Tips)
(Tip provides 1/8" set back)
3/64" (1.2mm)
1/16" (1.6mm)
3/32" (2.4mm)
Aluminum
Aluminum
Aluminum
15165
15166
15167

10757
10757 - .045" (1.15mm) Threaded
Copper Contact/Current Tip

Copper Contact/Current Tips - 5/16" Diameter Threaded

ORDERING INFORMATION - 5/16" DIAMETER THREADED
Gun or Barrel Model
Wire Size
Wire Type Code No.
All HTC, HTM, CTW, CW-C, CW-T, MTW
(Threaded Tips)
(Tip provides 1/8" set back)
.035" (.9mm)
.045" (1.2mm)
.052" (1.4mm)
1/16" (1.6mm)
5/64" (2mm)
3/32" (2.4mm)
Hard
Hard
Hard
Hard
Hard
Hard
10756
10757
10841
10759
10761
10763
All HTC, HTM, CTW, CW-C, CW-T, MTW
(Threaded Tips)
(Tip provides 3/8" set back)
.045" (1.2mm)
1/16" (1.6mm)
5/64" (2mm)
3/32" (2.4mm)
7/64" (2.8mm)
Cored
Cored
Cored
Cored
Cored
10750
10751
10752
10753
10754


10911 - .045" (1.15mm) Bullet Threaded
Copper Contact/Current Tip

Copper Contact/Current Tips - 5/16" Diameter Bullet Threaded

ORDERING INFORMATION - 5/16" DIAMETER BULLET THREADED
Gun or Barrel Model
Wire Size
Wire Type Code No.
All HTC, HTM, CTW, CW-C, CW-T, MTW
(Threaded Tips)
(Tip provides 1/8" set back)
.030" (.8mm)
.035" (.9mm)
.045" (1.2mm)
.052" (1.4mm)
1/16" (1.6mm)
Hard
Hard
Hard
Hard
Hard
10909
10910
10911
10912
10913


15183 - 3/32" (2.4mm) "BIG MIG" Slip-In
Copper Contact/Current Tip

Copper Contact/Current Tips - 7/16" Diameter "BIG MIG" Slip-In

ORDERING INFORMATION - 7/16" DIAMETER SLIP-IN
Gun or Barrel Model
Wire Size
Wire Type Code No.
NCM15 ("BIG MIG")
(Slip-In Tips)
(Tip provides 1/8" set back)
1/16" (1.6mm)
5/64" (2mm)
3/32" (2.4mm)
7/64" (2.8mm)
1/8" (3.2mm)
5/32" (4mm)
Cored
Cored
Cored
Cored
Cored
Cored
15181
15182
15183
15184
15185
15186
NCM15 ("BIG MIG")
(Slip-In Tips)
(Tip provides 1/8" set back)
1/16" (1.6mm)
3/32" (2.4mm)
1/8" (3.2mm)
5/32" (4mm)
3/16" (4.8mm)
7/32" (5.6mm)
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
10798
10799
10800
15186
15169
15170








15062 - .045" (1.15mm) Bent Slip-In
Copper Contact/Current Tip

Copper Contact/Current Tips - 1/4" Diameter Bent Slip-In

ORDERING INFORMATION - 1/4" DIAMETER BENT SLIP-IN
Gun or Barrel Model
Wire Size
Wire Type Code No.
All NCC, NCM (Slip-In Tips)
(Tip provides 1/8" set back)
.035" (.9mm)
.045" (1.2mm)
3/64" (1.2mm)
1/16" (1.6mm)
Hard
Hard
Aluminum
Aluminum
15065
15062
15072
15073

Welding Tip Alloy Comparison - Genuine D/F American Torch Tips

Standard DHP (Regular Copper) - world wide standard excellent general purpose.

CuCrZr - (Cu-Copper Cr-Chromium Zr-Zirconium) a very hard alloy, has been around for years made for stainless steel and stiff, high column strength or abrasive wires such as Flux cored / Metal cored. If you are attempting to get a sure start you need to choose the best alloy, whether for electrical or physical wear. The next reason a tip wears is due to heat. As the tip heats from the welding process the properties of the alloys start to break down. The ability of the tip to dissipate the heat (thermal conductivity) will aid in keeping the tip cooler. The (electrical resistance) of the alloy is also inversely proportional to the electrical conductivity. As we need a sure start and are attempting to jump the gap from the contact tip to wire, these two factors play a critical role--if the tip has higher conductivity of electricity it will transfer the current easier (or with less resistance) which will also cause the tip to run cooler. Resistance equals heat. The additional benefit to higher conductivity is that the arc transfer from the tip to the wire is easier. Easier arc transfer means a superior sure start and less arc failure or wire burn back, sputtering and spatter.

There are 2 main reasons a welding tip wears:

  1. Common physical wear or abrasion, if you were to place a tip on the wire before the feeder with NO electrical contact, that tip would eventually wear completely through.
  2. Electrical erosion is similar to the brushes on an electrical motor or the spark jumping across the gap on a spark plug. For example, if the wire is traveling through the Contact tip at 300 IPM the electricity has to jump across from the copper tip to the "MIG" wire (Hence the name "Contact Tip"). The inside bore of the tip and the welding wire are in constant electrical arcing as this process is happening. Electrical erosion is melting of the welding tip ID.

Make sure the gun tip isn't worn out or that weld spatter is not on the tip near the exit hole. The contact tip in the gun should be perfectly round and just a few thousandths larger than the wire itself. Worn tips are typically oval and can cause an erratic arc from the random electrical connection and physical movement of the wire inside the worn tip. A genuine D/F Machine Specialties American torch tip is precisely made from a wear-resistant copper alloy for superior welding performance. If the contact tip enters the molten weld pool, it should be immediately replaced. For most casual welders, a good rule of thumb to assure high quality welding is to change the tip after ever 100 lbs. of wire. Another point to remember about contact tips is that they should always be threaded completely into the gas diffuser and tightened prior to welding to give a smooth flow of welding current.

D/F Machine Specialties is a family-owned and operated company that has been committed to producing American made products with American made materials for the last 45 years, and has been the innovator of all of its products. Quality and service are surpassed by no one. This attention to detail transfers to the customers receiving the finest American made welding products available on the market today.

 
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D/F® is the registered trademark of D/F Machine Specialties, Inc. D/F Machine Specialties, Inc. is not affiliated with Lincoln Electric®, Miller Electric®, ESAB®, Linde®, Tweco®, Thermal Arc®, Profax®, American Torch Tip®, Superior Consumables®, Fanuc Robotics®, Thermadyne®, ABB®, Hobart®, Kuka®, Mavrix®, American Weldquip®, Bernard®, Binzel®, Dinse®, Fronius®, M.K. Products®, Tregaskiss®, Motoman®, OTC Daihen®, Panasonic®, Welding Alloys®, Pandjiris®, Bug-O Systems®, CK Worldwide®, Weldcraft®, Airco®, Tec Torch®, CM Industries®, Alcotec®, and other MIG & TIG welding manufacturers. Those manufacturers mentioned are for reference only and are the registered trademarks of their respective companies.
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